off shore
2015 - 2016
UK Germany Asia America www.interarrayengineering.com info@interarrayengineering.com 0203 011 5087
CONTENTS intro wind farm portfolio
2 3
What we offer the package
5 6
PERSONNEL STRUCTURE
7
roles & RESPONSIBILITIES
8
DOCUMENT CONTROL
10
TErMINATION & TESTING
13
ELECTRICAL SAFETY CONTROL
14
OUR PRICES
15
SUPPLY OF TOOLS & MATERIALS
16
No.1 key solution provider for global cable installations
intro INTER ARRAY ENGINEERING has many years experience in various roles in the offshore wind industry. From representing clients to hands-on tools experience, we have carried out these diverse roles confidently and efficiently. With a combined 15 years in the OWF industry we believe we have the perfect combination to make any contract run as smoothly as possible. We understand that communication with the client, onshore management, and material suppliers are key to making a project a success. We strive to instil client confidence through our quality, timely management of deliveries and well informed onshore office. Inter Array Engineering have put together a complete OWF package to be offered to contactors of the main client to help streamline the whole installation process. To do this efficiently, we have learnt that a successful offshore management team equipped with the necessary skills and experience is crucial in taking a wind farm forward in a positive and productive way.
2
wind farm portfolio What offshore and onshore wind farms have the Inter Array Engineering partners worked on?
Offshore
Onshore
- Kentish Flats Extension - Baltic 2 - Dan Tysk - Global Tech 1 - BARD 1 - London Array - Ormonde - Robin Rigg - Walney 1 & 2 - Barrow
- Weather Hill - Knabs Ridge - Langley Park - Walkway High Swainston - Hagshaw - Broom Hill - West Durham - Lochhead - Great Eppleton - Lindhurst - Burnfoot - Harlock Hill - Bowbeat - Haveriagg - Crystal Rig - Cuach Mhor - Lambrigg - Tow Law - Greendykeside - Askam
3
On the listed wind farms, these are the roles various partners have performed: - Client Representative - Electrical Field Engineer - Appointed Person for HV Switching - Shift Supervisor - Offshore Coordinator - Permit Coordinator - Document Controller - Commissioning Manager - QA Manager - High Voltage Supervisor - Tower Supervisor - High Voltage Test Supervisor - High Voltage Jointer - High Voltage Jointer Assistant - Electrical Team Leader - Electrical Testing Supervisor - Electrical Technician
4
What we offer We are not an agency We check and confirm all offshore and trade certification. Supply on site training and conduct scheduled trade testing on all our staff. Supply an experienced management team. Cable containment design and cable route solutions. Schedule of planning. Document control. Permit control. HV/Electrical safety control and training. Quality assurance. Highly experienced termination and testing teams, both power and fibre optic. Our electrical inspectors can also represent clients to ensure a high quality install is achieved.
5
the package
Schedule of planning Once all project mock-ups have been completed and all data is collected we will produce a schedule of planning document. The document will break the job down into specific tasks and give estimations on how long each should take to complete (excluding any unforeseen issues and weather downtime). Work scopes can be added and deleted and variations to the work scopes times can be amended if/when necessary. The document can also be broken down into more detail if required. (See example from previous OWF below) Schedule of Planning for Completion of Asset on OWF
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Task Condition Assertion Protocol Hand Over Inspection of Asset for Defects Mobilisation of Asset With Offshore Support Unit, Generator, Heavy Tooling, Protection Preparation of Asset for Pull In Protection with Soft Cell, Rubber, Tooling/Winch Set up Pull in of Cable Operations conducted in tandem with Cable Laying Vessel Stripping Removal of Armour/Bitumen coating to reveal cable cores Post Pull IR Testing Test to ensure cable is sound, to enable continued works Temporary Hangoff Installation of Clamping Device and Stopper Plates Permenant Hang Off Installation of Gaskets, Itubes and "Chimney" Assembly Routing of Cable Routing of cable into specified helix (different configurations) Containment Building structure and cleating cable into fixed helix Post Containment Checklist Ensure containment is within acceptable criteria to move forward Terminations Termination of 3 cores using EuroMold Tee Boots and Accessories Cold Commissioning Project Specific conbination of Phase ID, IR, TDR, VLF Testing Resin Pour Pouring of resin into the hangoff creating an air tigyt seal Inspection of Complete Installation by Client Representative using Check Project Specific Checklist Condition Assertion Protocol Hand Over Inspection of Asset for Defects
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 R R Project Management/Client Rep Rigging Team Stripping Team Mechanical Team Inspection of all cable cores after stripping
Termination Technicians Testing Team Client Representitive Present
R
Inspection Point by Asset Supervisor, predetermined checklist referred to. Inspection Point by Asset Supervisor, predetermined checklist referred to.
R R R R R R R R R
R R R R
This schedule is typical of the average installation sequence. It can be broken down further if required, with applicable milestones added. This data is realtime data. If works are carried out simultaneously with another cable into the same asset, of course times per cable will be reduced. Created 25/4/15 Version 001 -‐ James Madden
6
Personnel Structure Below is an example layout of the package on offer. Positions circled in red are not supplied in the Inter Array package, however, we can supply them as additional services. If the contract consists of day and night shift working, all roles within the package will be 24-hour roles and will require two of each position per rotation. Past experience has shown a drop in productivity and a rise in issues during night shifts because of lack of management, so this is something we are keen to remedy. Productivity is key to any project, so we at Inter Array Engineering endeavour to keep the productivity as high as possible, ensuring we hit the client’s milestones. The resource proposal can be tailored to your individual needs as you may not require the full package, or may need a different skill set depending on the job at hand.
Pre Windfarm Agreement Team Electrical Engineer
Proposal Manager
T&T Manager
windfarm management/termination & test team Clients Offshore Personnel Your Offshore Personnel Electrical Field Engineer Shift Supervisor MV/HV & Fibre QA Inspector 1 HV Tower Team
Storeman / Materials Controller
Fibre Optic Tower Team
MV/HV & Fibre QA Inspector 2
HV Tower Team
Fibre Optic Tower Team
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roles & responsibilities Electrical Engineer & Proposal Manager As part of the pre windfarm agreement team the electrical engineer will be working alongside the proposal manager, tailoring all documentation specifically for the upcoming windfarm project. All of Inter Array’s basic templates are amended to suit any contract. This means when the contract starts, all of the documentation is ready to use, which is vital to ensure no delays or missed information from the word go. Electrical Field Engineer The electrical field engineer is responsible for maintaining the electrical quality and workmanship of the installations, ensuring prescribed step-by-step instructions are followed, dealing with queries from installation teams, putting in place a plan for installation team allocation, deciding which locations are to be worked on, and what work will be carried out that working day. Shift Supervisor The shift supervisor is responsible for the management of the installation teams, as well as overseeing shift changes and vessel movements. The shift supervisor will use the plan drawn up by the electrical field engineer to allocate teams, equipment, and materials to each of the working open locations. Storeman/Materials Controller The storeman/materials controller will be responsible for issuing and recording all tools, PPE, and materials. All tools must be signed in and out by the storeman to the team leader prior to the shift starting. The storeman will keep control of all stock checks, and if anything is required send the relevant order to the onshore site manager with enough lead time so the project does not succumb to delays. Project Document Controller The project document controller will be responsible for the upkeep of all daily progress documentation and will work alongside the shift supervisor and electrical field engineer. The project document controller will also carry out any tasks allocated by the Offshore Installation Manager (OIM) to help with the running of daily workflow. MV/HV & Fibre QA Inspector The QA inspector is responsible for on site task specific tool box talks with the installation teams, setting timescales and achievable targets whilst on assets, carrying out spot checks, and general supervision of engineers and accompanying client representatives when it is important to witness certain tasks. During weather downtime, training will be used to develop the skill set of the technicians, ensuring quality is maintained.
8
Mock up cable route HV Test Engineer The HV test engineer will be solely responsible for the HV testing of the inter array cables once the terminations are complete. They are responsible for the safety of all personnel during the testing stage making sure all of the appropriate safety measures and signs are in place. The HV test engineer will report directly to the electrical field engineer and shift supervisor. MV Termination Technician 33kV The MV termination technician will be tower team leader and responsible for the 33kV terminations on the tower. They will make sure their team completes all work scopes to procedures and that all paperwork is complete and handed to the project admin or shift supervisor. Fibre Optic Technician The fibre optic technician will be tower team leader and responsible for the fibre optic terminations and testing on the tower. They will make sure their team completes all work scopes to procedures and that all paperwork is complete and handed to the project admin or shift supervisor. Termination Support/Electrician The termination support will be ‘mates’ for the MV and fibre optic technicians and help carry out tasks such as cable stripping, routing, cleating, and general support.
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document control Project Progress Tracker
A ‘one-stop’ document will be designed and implemented detailing the bespoke milestones for the project. This document will include the information that the client and onshore management team need to monitor, and will help determine likely finish dates. Also recorded is the name of the team leader who completed the work for future accountability if any problems arise. The shift supervisor is responsible for keeping this up to date on a daily basis. An example of this document used on a previous project is below.
PROGRESS TRACKER - CLUSTER 4 Project: Baltic 2 Offshore Wind Farm IAG
Contract: 0945
Asset
Cable Ref
Cable from
Cable to
Baltic 2 I6
W141AAF02WB070
I6
OSS
W141AAF05WB071
I6
I5
Baltic 2 I5
W141AAF05WB071
I5
I6
W141AAF08WB072
I5
I4
Baltic 2 I4
W141AAF08WB072
I4
I5
W141AAF11WB073
I4
J3
Baltic 2 J3
W141AAF11WB073
J3
I4
W141AAF14WB074
J3
J2
Baltic 2 J2
W141AAF14WB074
J2
J3
W141AAF17WB075
J2
J1
Baltic 2 J1
W141AAF17WB075
J1
J2
W141AAF20WB076
J1
K1
As Found Hand Over 06/08/14
21/08/14
25/08/14
29/08/14
30/08/14
03/09/14
Cable Pull Temp In Hang Off
Pull In
Perm Hang Off
Last Update: 8th September 2014
Terminations Phase ID
Post Pull IR Test
Cable Stripped
Cable Routing
Term Fibre
Term HV Cores
08/08/14
08/08/14
08/08/14
09/08/14
22/08/14
22/08/14
22/08/14
22/08/14
25/08/14
25/08/14
25/08/14
25/08/14
26/08/14
26/08/14
26/08/14
26/08/14
07/09/14
03/09/14
29/08/14
29/08/14
29/08/14
01/09/14
01/09/14
29/08/14
07/09/14
03/09/14
03/09/14
29/08/14
29/08/14
29/08/14
01/09/14
01/09/14
30/08/14
01/09/14
01/09/14
01/09/14
29/08/14
29/08/14
29/08/14
30/08/14
30/08/14
02/09/14
30/08/14
30/08/14
30/08/14
31/08/14
31/08/14
03/09/14
03/09/14
03/09/14
03/09/14
03/09/14
03/09/14
03/09/14
04/09/14
04/09/14
04/09/14
03/09/14
04/09/14
04/09/14
05/09/14
Phase ID & Continuity
Conductor Resistance
Commissioning IR Test
Sheath Test
TDR Test
OTDR Test
Finalisation VLF Test
Resin
Final Hand Over
Daily Action Log During the working 24-hour day it is good practice to record certain crucial events in a daily action log. This document is live and changes based on updates received from the tower team leaders via UHF. This information is usually kept in-house and can be used to produce the DPR as well as update all other progress documentation. An example of this is below.
Daily Action Log Project: Baltic 2 Offshore Wind Farm IAG
Date: 7th September 2015
00:00 - STBY at K5 in DP 00:10 - Ampelmann connected to K5, 3x ASP OFF 00:15 - Transit from K5 to L4 00:35 - Arrival at L4 (2nd pull end) 00:45 - Ampelmann connected at L4 shift change 3x ASP 00:50 - STBY at L4 in DP 01:30 - L4 completely prepped for second end pull waiting for Olympic Commander 02:30 - Olympic commander informs L4 they will be ready in one hour 04:20 - L4 second end pull starts (Rep AE) 06:00 - Ampelmann connected to L4, 3x BB plus 1x EnBW (AE) OFF and 3x BB plus 1 EnBW
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Daily Progress Report This report is the official document that is assessed by the client daily. This is a very important document as it gives all information from the previous 24-hours. The report will include; all personnel on site, how many days each person has worked, work completed that day, any issues that have arisen, and any client downtime. The DPR is then approved and signed by the OIM and senior client representative. Permit to Work Control No personnel will be allowed to access a WTG asset until a valid permit to work is in place for that location. This is a vital part of the document control as delays in permits mean delays in work, which can be detrimental to the cost control of the whole project. We at Inter Array Engineering look to improve the monitoring of PTW that are needed for the planned daily works. We will make sure these are in place, approved, and the PTW issued to the team leader.
PERMIT TO WORK RECORD PTW No. PTW 0001 PTW 0002 PTW 0003 PTW 0004 PTW 0005 PTW 0006 PTW 0007 PTW 0008 PTW 0009
Start Date 07/07/14 08/07/14 09/07/14 09/07/14 09/07/14 12/07/14 12/07/14 17/07/14 17/07/14
End Date 10/07/14 11/07/14 12/07/14 12/07/14 12/07/14 17/07/14 17/07/14 20/07/14 20/07/14
Contractor SOC SOC SOC SOC SOC SOC SOC SOC SOC
Work Scope Cable Pull In & Stripping Cable Pull In & Stripping Cable Pull In & Stripping Hang Off & Containment Hang Off & Containment Cable Routing Cable Routing HV Terminations HV Terminations
Asset J6 J5 J4 J6 J5 J6 J5 J6 J5
Open / Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed
Procedure No. for Work Scope B2_IAG_Siem_P012-‐0945-‐IP-‐011-‐Cable-‐Pull-‐In-‐Procedures-‐Monopiles-‐Rev.5 B2_IAG_Siem_P012-‐0945-‐IP-‐011-‐Cable-‐Pull-‐In-‐Procedures-‐Monopiles-‐Rev.5 B2_IAG_Siem_P012-‐0945-‐IP-‐011-‐Cable-‐Pull-‐In-‐Procedures-‐Monopiles-‐Rev.5 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2 B2_IAG_Siem_P012-‐0945-‐IP-‐015-‐Termination-‐and-‐Testing-‐Procedure-‐Rev.2
Stock/Materials Control As a part of the storeman/materials coordinators role they will be solely responsible for the upkeep of all documents relating to stock of employer issued materials, contractor materials, PPE, tools, and consumable materials. Tools will be on a sign-in and sign-out system eligible to the team leaders only.
Employer Issued Materials Stock Client: EnBW Erneuerbare Energien GmbH Admiralitaetstrasse 4 20459 Hamburg Germany Project: Baltic 2 OWF No. 1 2 3 4 5 6 7 8 9 10
Component 630 Hang Off 300 Hang Off Hang Off Earthing Cable (50mm) (m) 50mm Lug for Hang Off Earthing 630 T Connectors 300 T Connectors Cleats VRT +09 (630 Trefoil) Cleats VRT +07 (300 Trefoil) Cleats VRT +02 (Single 300 & 630) Cleats Flexistrap 630
ISV 30 30 350 100 37 45 240 345 210 141
Warehouse 15 27 300 150 19 150 42 52 6 7
Total Stock 45 57 650 250 56 195 282 397 216 148
Required 60 45 0 250 125 130 102 156 256 187
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Punch List The punch list will be updated with all snagging items from each WTG once they are highlighted. This will show all small items still outstanding that will stop the handover of the asset to the client. Below is an example of the punch list document used on a previous contract. PUNCH LIST - CLUSTER 4 Project: Baltic 2 Offshore Wind Farm IAG
Asset I6 I4 I4 J3 J1 J4 J4 J5 J5 J5 J5 J5 J5 J6 J6 J6
Contract: 0945
Date
Engineer
Cable
Comments
06.09.2014 06.09.2014 06.09.2014 06.09.2014 06.09.2014 06.09.2014 28.07.2014 28.07.2014 28.07.2014 28.07.2014 30.07.2014 30.07.2014 28.07.2014 28.07.2014 30.07.2014
DH DH DH DH DH DH GS JM JM PK PK PK JM JM PK
North & South North & South
Labels Single cleats VR+03 replace with VR+02
South
North & South North & South North & South South South South South South South
North North North
Closed Date
Checked By
Time Taken
Comments
Photo No.
Big scuff needs graphite repair Labels
Labels Final Hang Off earth to be fitted and picture taken Cleating of power cores Labels Data Logger to be installed Picture to be taken of Permanent Hangoff (Earthing must be visible) Picture of Fiber Optic Cable Routing missing. Picture of Splicebox missing. Cleating of power cores Cable Tag missing 400mm above Hang-‐off Picture of Fiber Optic Cable Routing missing.
Five Day Look Ahead The Inter Array Engineering management team uses a basic five day look ahead document (see below example). The client will issue a programme of works or a priority work list, this data is then transferred into the plan of works and assigned to the correct teams. This process helps with the planning of permits so they can be prepared ready for the coming day’s work.
5 DAY LOOK AHEAD Project: Baltic 2 Offshore Wind Farm IAG
Date 15 September 2014
16 September 2014
17 September 2014
Contract: 0945
Planned Work Team 1 -‐ J4 -‐ HV Termination Works Team 2 -‐ J6 -‐ Fibre Optic Termination Work & OTDR (J6-‐J5) Team 3 -‐ J5 Fibre Optic Termination Work & OTDR (J5-‐J6) Team 1 -‐ J4 -‐Complete HV Termination Work & Move to J5 for HV Cable Routing Team 2 -‐ J4 -‐ Fibre Optic Termination Work Team 3 -‐ J3 Fibre Optic Termination Work Team 1 -‐ Complete J5 for HV Cable Routing and start HV Terminations Team 2 -‐ J4 -‐ OTDR Test (J4-‐J5 & J4-‐J3) Team 3 -‐ J5 OTDR Test (J5-‐J4) J3 OTDR Test (J3-‐J4)
We can provide you with the whole package
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termination
& testing
As well as an experienced management team, Inter Array Engineering also provides a highly experienced termination and testing team. All technicians that complete the final terminations are land-accredited jointers with Lloyds accreditations as well as having previous experience working for the local/national electricity board. The HV termination manager has 20 years experience on over 30 wind farms in various roles, both on and offshore. Roles range from HV cable jointer to client representative. The HV termination manager uses his vast knowledge and experience to ensure an extremely high standard is delivered throughout the project. If outside personnel are used on a project, the management team thoroughly interview and trade test all candidates prior to starting in any position with Inter Array Engineering.
testing services include Conductor Resistance HV Termination Services include Vast experience of installing all hang-offs used in the OWF industry so far. Most recently installing VOS, Nexans & Henley cable hang offs.
Time-domain Reflectometer (TDR) Insulation Resistance Sheath testing Very Low Frequency (VLF)
Cable containment design and assembly Routing and cleating of the HV Cables into the switchgear / termination box Preparation of cable ends for termination of the bolted T Connectors Termination of array and export cables Experience of Euromold, NKT & Pfisterer
fibre optic services Local accredited fibre optic company Routing and cleating of the FO cable Termination and Splicing OTDR Testing Production of OTDR Test Report
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electrical safety
control & training Competent Person Training Under the Health and Safety at Work Act 1974 and other legislation, the employer has an obligation to provide safe places to work and safe systems of work. Inter Array Engineering has developed a Competent Person Training Course to familiarise contractors with the following: - Safe working on isolated equipment and their responsibilities associated with receiving and working under a permit to work in accordance with electrical safety rules and approved procedures. - Hazard awareness and appropriate safety precautions to staff who require access to substations. - Relevant information with regards to the lock out/tag out systems used. project specific training/trade testing Inter Array provide this unique service so you have the peace of mind that all personnel will arrive on site fully vetted and trade tested to your project specifics. - Termination trade test - Mock up of cable hang off - Mock up of cable routing and cleating - Mock up TDR, CR, IR and VLF tests will be performed so all testing technicians will be familiar with the test equipment being used.
Our highly experienced termination and test manager will oversee all of the above making the install as streamlined as possible.
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our prices Below is a list of the Inter Array Engineering prices, (the prices are for labour only).
role
rate
Electrical Field Engineer
£840
Shift Supervisor
£770
MV/HV QA Inspector
£655
Fibre QA Inspector
£655
Project Document Controller
£600
MV Termination Techbician 33kv
£600
Fibre Optic Technician/Tester
£600
HV Test Engineer
£600
Termination Support/Electrician
£480
Materials Coordinator
£440
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supply of
tools & materials
In the offshore wind industry there are many types of specialist tools used as well as general hand tools. Inter Array Engineering has access to all tools and materials needed through accounts held with electrical and jointing wholesalers. These can be used at the clients discretion. Realistic timescales will always be given on delivery of materials and tools.
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www.interarrayengineering.com info@interarrayengineering.com 0203 011 5087
No.1 key solution provider for global cable installations
UK Germany Asia America www.interarrayengineering.com info@interarrayengineering.com 0203 011 5087